System and Method for Inspecting Fused Plastic Pipes

ABSTRACT

A method and apparatus for testing a fuse between plastic pipes within a fusion socket performed in the field includes a source of X-ray radiation and a scanning plate that has pixels that change state when exposed to this radiation. The source of the X-ray radiation is positioned on one side of the fuse and the scanning plate is positioned on another side so that the x-ray radiation passes through the fuse. After exposure, the x-ray image from the scanning plate is analyzed visually or algorithmically to find internal voids, weak fuses, and evidence of movement after the plastic of the fitting/pipes melted and flowed together. With such, the quality of the fitting is evident without cutting or otherwise destroying the fitting and, therefore, only weak or otherwise compromised fittings need be cut and redone.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation in part of U.S. patent applicationSer. No. 16/504,825, filed Jul. 8, 2019, the disclosure of which ishereby incorporated by reference.

FIELD

This invention relates to the field of plastic pipes and moreparticularly to a system and method for nondestructive inspecting fusedpipes.

BACKGROUND

In recent years, more and more plastic pipe has been deployed in fluiddistribution systems, for example, natural gas, liquid natural gas,water, etc. Plastic pipe (e.g., polyethylene pipe) has many advantagesover prior iron pipe, including greater resistance to corrosion, quickerand simpler splicing (iron pipe is typically welded), and lower weightimproving transportation, safety, and installation equipmentrequirements, etc.

Some such plastic pipe comes in coils, allowing for extremely long runswithout splices, sometimes 250-500-foot runs, while larger diameterplastic pipe typically comes in shorter lengths requiring more splicesper mile.

One way to fuse two plastic pipes is to heat the end of each plasticpipe to the melting point of the plastic, then push the molten ends ofthe pipes together and held until the plastic solidifies. This method,called butt fusion, produces a workable bond between the two lengths ofplastic pipe, but requires great precision and technique in holding bothends of the pipe in play until proper cooling has completed. Often,using this method, some of the molten plastic encroaches on the innerdiameter of the pipe. Also, once bonded, one cannot see how much plasticfrom each pipe flowed together and, therefore, one cannot easily tell ifthe bond is good.

Another method of fusing plastic pipe (or attaching a tap or installinga ‘T’) is called socket fusion. In socket fusion, a fitting is used inwhich one plastic pipe is inserted into a first end of the fitting,another plastic pipe is inserted onto another end of the fitting, thenan electric voltage is applied to resistive wires that are wound insidethe fitting, thereby melting the inner diameter of the fitting and theouter diameter of the pipe so that the plastic from the fitting an theplastic from the pipe bond together. After the electric voltage isdiscontinued, the plastic solidifies making a proper Joint. In such, itis important that the pipes and fitting not be moved until cooling hascompleted.

In all versions of fusing of plastic pipe, after the fusing is complete,it is difficult to determine if the fusing was done correctly, as thereis typically no or little external evidence of a faulty fusingoperation. For example, with socket fusing, unless the pipes arenoticeably skewed off axis, there is no way to tell if the pipes weremoved during cooling, whether the pipes were not close enough to eachother during fusing, etc.

In the past, the only way to tell if two pipes are properly fused was tocut out the section of pipe that was fused and cut cross-sections of thefuse area for inspection with magnifying glasses, etc. Of course, thetwo pipes then need to be fused together again, probably by the samefuser as the fuser that performed the original fusing. This method ofinspection provides a statistical basis for the quality of the fusings,and likely, the quality of similar fusings performed on the same day.

To date, there were no methods and apparatus for determining the qualityof a fusing without such destruction.

What is needed is a system that will detect weak or faulty fusings (badfusings) without destroying those fusings that are good.

SUMMARY

A method and apparatus for testing a fusing without destroying thefusing is disclosed. As such fusing is performed in the field, it ispreferred that the testing be performed in the field as well. Thetesting includes a source of X-ray radiation and a scanning plate thathas pixels that change state when exposed to the radiation. The sourceof the X-ray radiation is positioned on one side of the fusing and thescanning plate or scanning device is positioned on another side of thefusing so that the x-ray radiation passes through the fitting. Theradiation radiates the fusing making visible internal voids, weakfusings, and evidence of movement after the plastic of the fitting/pipesmelted and flowed together. With such, the quality of the fitting isevident without cutting or otherwise destroying the fitting and,therefore, only weak or otherwise compromised fittings need be cut andredone.

In one embodiment, an apparatus for non-destructive testing of a fusebetween plastic pipes inserted into a fusion socket is disclosedincluding a source of radiation selectively operated to emit an x-rayradiation, a computer, a scanning plate for receiving the x-rayradiation, a scanner that is operatively coupled to the computer and adisplay operatively coupled to the computer. The source of radiation ispositioned on one side of the fuse between the plurality of plasticpipes and the scanning plate receives the x-ray radiation that passesthrough the fuse while the source of radiation is selectively operatedto emit the x-ray radiation. After the source of radiation isdiscontinued, the scanning plate is moved to the scanner and the scannerscans the scanning plate into an x-ray image that is transferred into astorage of the computer. The computer analyzes the x-ray image of thefuse and recognizes a position of each of the plurality of plastic pipesto determine if the fuse is a bad fuse by the position of each of theplurality of plastic pipes.

In another embodiment, a method of determining if a fuse between plasticpipes within a fusion socket is a bad fuse. The method includes placinga source of x-ray radiation that emits x-ray radiation on one side ofthe fuse and holding a scanning plate (or scanning device) to anopposing side of the fuse. After the emission of the x-ray radiation thescanning plate is removed from the opposing side of the fuse and movedto a scanner. The scanning plate is scanned to create an x-ray image ofthe fuse which is transferred into a storage of a computer and displayedon a display of the computer. The x-ray image of the fuse is visuallyanalyzed to determine if the fuse is the bad fuse by recognizing aposition of each of the plurality of plastic pipes to determine if thefuse is the bad fuse by the position of each of the plurality of plasticpipes within the fusion socket.

In another embodiment, a method of determining if a fuse between plasticpipes within a fusion socket is a bad fuse includes placing a source ofx-ray radiation on one side of the fuse and receiving the x-rayradiation an opposing side of the fuse to create an x-ray image of thefuse from the radiation received at the opposing side of the fuse. Thex-ray image is stored in a storage of a computer and then displayed on adisplay of the computer. It is determined if the fuse is the bad fuse byreading and analyzing the x-ray image and determining if the fuse is thebad fuse by finding, in the x-ray image, any of the following issues: agap between two of the plastic pipes being greater than a predetermineddistance, an end of one of the plastic pipes being further than apredetermined distance from a length-wise center of the fusion socket,or an end of one of the plastic pipes being inserted to far within thefusion socket, thereby blocking flow to a second one of the plasticpipes.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be best understood by those having ordinary skill inthe art by reference to the following detailed description whenconsidered in conjunction with the accompanying drawings in which:

FIG. 1 illustrates a schematic view of a method of fusing of the priorand current art.

FIG. 2 illustrates a failure report of the prior art after destructivetesting of fused plastic pipes.

FIG. 3 illustrates a view of an x-ray imaging system of the system fornon-destructive testing.

FIGS. 4 and 5 illustrate x-ray images taken by imaging system of thesystem for non-destructive testing.

FIGS. 6, 7, and 8 illustrate x-ray images taken by imaging system of thesystem for non-destructive testing.

FIGS. 9 and 10 illustrate x-ray images taken by imaging system of thesystem for non-destructive testing.

FIGS. 11, 12, and 13 illustrate x-ray images taken by imaging system ofthe system for non-destructive testing.

FIGS. 14 and 15 illustrate x-ray images taken by imaging system of thesystem for non-destructive testing.

FIG. 16 illustrates an x-ray image taken by imaging system of the systemfor non-destructive testing.

FIG. 17 illustrates an x-ray images of a tee joint taken by imagingsystem of the system for non-destructive testing.

FIGS. 18 through 21 illustrate x-ray images of an electrofusion servicetee taken by imaging system of the system for non-destructive testing.

FIG. 22 illustrates a schematic view of the system for non-destructivetesting.

FIGS. 23-24 illustrate exemplary flow diagrams of the system fornon-destructive testing.

FIG. 25 illustrates a schematic diagram of the computer of the systemfor non-destructive testing.

DETAILED DESCRIPTION

Reference will now be made in detail to the presently preferredembodiments of the invention, examples of which are illustrated in theaccompanying drawings. Throughout the following detailed description,the same reference numerals refer to the same elements in all figures.

In the current art, more and more plastic pipe is being deployed fordistribution of many different fluids (gases or liquids) such as waterand fuel gases (e.g., natural gas or liquid natural gas). As suchplastic pipe is delivered in sections or in rolls, the current artutilizes several methods of joining two sections (or three sections in atee) of the plastic pipe, such as butt fusion or socket fusion. Thesemethods of fusion share one common issue—once the ends of two pipes arefused, it is almost impossible (using current art methods) to determineif the fuse is good and will withstand flexing and expected pressures.

Referring to FIG. 1 , a schematic view of a method of fusing of theprior and current art is shown. Note that this is but one example of howtwo sections of plastic pipe 6 are fused and not meant to beall-inclusive.

In this example, the ends of two sections of plastic pipe 6 are prepared(e.g., cleaned and in some cases, rotary shaved), then each section ofplastic pipe is lifted off the ground (e.g., by sawhorses 3) andinserted into a fusion socket 8. Next, an electric potential (e.g., froma battery 1 through a switch 2) is applied to electrical terminals 9 ofthe fusion socket 8. Not visible is a coil of resistive wire 7 (e.g.,see FIG. 4 ) that is wound internally to the fusion socket 8 runningfrom one of the electrical terminals 9 to the other of the electricalterminals 9. When the electric potential is applied to the electricalterminals 9, the resistive wire 7 heats, melting some of the plastic ofan outside surface of the plastic pipe 6 and an inside surface of thefusion socket 8. After the electric potential abates (e.g., the switch 2is turned off), the now co-mingled plastic cools, forming a strong bondbetween each end of the plastic pipe 6 and the fusion socket 8.

There are many things that can go wrong when fusing two of the plasticpipes 6, caused by, for example, moving either of the plastic pipes 6before proper cooling, over shaving or uneven shaving of each end of theplastic pipes 6, not cutting each of the plastic pipes 6 at almostexactly 90 degrees, etc. FIGS. 3-21 show examples of plastic pipes 6that are fused as displayed by the system for non-destructive testing.

Referring to FIG. 2 , a failure report after destructive testing offused plastic pipes of the prior art is shown. In the prior art,inspectors periodically, and randomly, select samples of fuses betweenplastic pipe 6 to make sure a particular fuser (a person who fuses theplastic pipe 6—similar to a welder of iron or steel pipe) is making goodfuses. In the example failure report 100 of FIG. 2 , the fuser's name102 and type/location of the plastic pipe 6 and fuse are recorded. Apicture of the plastic pipes 6 and fusion socket 8 with electricalterminals 9 is shown before the samples are cut. Each sample is cut outof the plastic pipes 6, then cut into strips and examined to determineif that sample had been fused properly. In this example, heavy scrapes106 were found, measuring 0.031″ with a caliper 104 when the maximumallowable tolerance is 0.007″. This type of fusion often results in lessmelting of the plastic pipe 6, thereby leading to a weak bond betweenthe plastic pipe 6 and the fusion socket 8 that, after burying underdirt, highways, etc., often begins to leak.

The information provided by such destructive testing is somewhat of ameasurement of the care and quality of the fuser, so if this fuse issuspect, it is likely that other fuses by the same fuser are alsosuspect and need to be inspected and likely redone.

Unfortunately, since the plastic pipe 6 was cut to take the abovesample, it now has to be fused again, often by the same fuser.

Referring to FIG. 3 , a view of an x-ray imaging system of the systemfor non-destructive testing is shown. In this example, the plastic pipes6 are shown held by saw horses 3 and the fuse (in this example, with afusion socket 8 having electrical terminals 9 are shown.

A source of radiation 150 is held in position, for example, by legs 156of a tripod. The source of radiation 150 is remotely controlled to emitradiation (e.g., x-rays) (optionally through a lens 152) and directed atthe fuse. In some embodiments, the lens 152 is made of a material suchas Beryllium which allows enough radiation out of the source ofradiation so as to penetrate the fuse, but a lower amount of radiationso as to not radiate harmful radiation towards operators of the sourceof radiation.

Preferably, on the opposing side of the fuse is a scanning device or ascanning plate 154 such as a phosphorous plate. The scanning plate 154records exposure to radiation across the surface of the scanning plate154. The scanning plate 154 is held to the plastic pipe 6 at the fuse byany desired mechanism (e.g., using tape, resilient straps, rigs . . . ).As will be shown with FIG. 22 , after the source of radiation 150 isactivated (initiating emission of x-ray radiation) for a period of timeand the scanning plate 154 is exposed to the radiation through the endsof the plastic pipe 6 and the fusion socket 8. The source of radiation150 is deactivated (stopping) emission of x-ray radiation) and thescanning plate 154 is scanned into an image by placing the scanningplate 154 is placed on a scanner 160 (see FIG. 22 ), which also erasesthe scanning plate 154 so that it is ready for the next scan.

Now several examples of images captured by the system fornon-destructive testing will be shown and described.

Referring to FIGS. 4 and 5 , x-ray images taken by imaging system of thesystem for non-destructive testing are shown. The resistive wire 7 ofthe fusion socket 8 is shown wrapped in a spiral within the fusionsocket 8. There are two issues highlighted in FIG. 4 . The first is agap 112 between the ends of the plastic pipe 6 and the fusion socket 8.There is a predetermined tolerance (e.g., predetermined distance)allowed for a gap 112 between the ends of the plastic pipe 6 and thefusion socket 8, typically set by local or nation-wide codes for fusionof plastic pipes 6. The second is an uneven or irregular spiral of theresistive wire 7, as the resistive wire 7 (before heating) is evenlywound with each turn of the resistive wire 7 separated from eachsuccessive turn of the resistive wire 7. These are examples of a badfuse that is likely to fail once the plastic pipe 6 is pressurized or atsome time before the expected end-of-life of the pipeline. In thehighlighted area, there is an uneven spiral 110 as the windings of theresistive wire 7 are uneven and successive turns touch each other. Thisis evident of movement of the plastic pipe 6 before the plastic has hadsufficient time for cooling. In FIG. 5 , a good fuse is shown as evidentby a lack of gaps (gaps 112 in FIG. 4 ) and a relatively even spiral ofthe resistive wire 7.

Referring to FIGS. 6, 7, and 8 , x-ray images taken of a butt fuse byimaging system of the system for non-destructive testing are shown. InFIG. 6 , the x-ray image shows an uneven fuse 118 (an example of a badfuse), likely caused by dirt on the ends of the plastic pipes 6 beforefusing. In FIG. 7 , a void 116 has been detected in the x-ray image(another example of a bad fuse). Such a void will leak once the plasticpipe 6 is put under pressure. In FIG. 8 , a good butt fuse is shown inwhich the ends of the plastic pipe were properly cleaned, properlyheated, and held together without movement until the fuse solidified.

Referring to FIGS. 9 and 10 , x-ray images taken by imaging system ofthe system for non-destructive testing are shown. The resistive wire 7of the fusion socket 8 is shown wrapped in a spiral within the fusionsocket 8. There are two issues highlighted in FIGS. 9 and 10 . The firstis voids 111 between the ends of the plastic pipe 6 and the fusionsocket 8. According to current standards, small voids are allowable, forexample, up to 10% of the fusion zone length, or even smaller voids 111in which the combined void size is less than 20% of the fusion zonelength.

The second is an uneven spiral 110 of the resistive wire 7, as theresistive wire 7 (before heating) is evenly wound with each turn of theresistive wire 7 separated from each successive turn of the resistivewire 7. In the highlighted area, there is an uneven spiral 110, thewindings of the resistive wire 7 are uneven and successive turns toucheach other. This is evident of movement of the plastic pipe 6 before theplastic has had sufficient time for cooling. These are examples of a badfuse.

Referring to FIGS. 11, 12, and 13 , more examples of x-ray images takenby imaging system of the system for non-destructive testing are shown.The resistive wire 7 of the fusion socket 8 is shown wrapped in a spiralwithin the fusion socket 8. Again, there is an uneven spiral 110 of theresistive wire 7, with the resistive wire 7 likely shorting to itselfduring heating creating hot spots and cold spots. This uneven spiral110, the windings of the resistive wire 7 is evident of movement of theplastic pipe 6 before the plastic has had sufficient time for cooling.In FIG. 13 , another issue with the fuse is evident. There is a gap 120of 0.624 inches between the ends of the two plastic pipes 6. Thiscreates a reliance totally on the strength of the fusion socket 8 in thearea of the gap 120, possibly leading to a rupture once the plasticpipes 6 are pressurized. This is an example of a bad fuse.

Note that many local or nation-wide codes specify a maximum gap 120 ordistance allowed between the ends of the plastic pipes 6.

Referring to FIGS. 14 and 15 , x-ray images taken of a tee fusion socketjoining three plastic pipes 6 by imaging system of the system fornon-destructive testing are shown. In the case of a fusion tee 8A, it isimportant not to insert the ends of the plastic pipe 6 too far into thefusion tee 8A, as if the ends of the plastic pipe 6 are inserted too farinto the fusion tee 8A, the ends of the plastic pipe 6 will block flowof the fluid to the third leg of the fusion tee 8A. The resistive wire 7of the fusion tee 8A is shown wrapped in a spiral within the fusion tee8A. There is only slight skewing of the resistive wire 7 but there isother evidence that the plastic pipe 6 was moved before the meltedplastic of the plastic pipe 6 and the fusion tee 8A sufficientlyhardened. In FIG. 15, the ends 122 of the plastic pipes 6 intrude uponthe third leg of the fusion tee 8A. This reduces the amount of fluidthat will flow to the third leg of the fusion tee 8A. Such intrusion iseven more evident in FIG. 17 where a first one of the plastic pipes 6completely blocks a second one of the plastic pipes 6.

Referring to FIG. 16 , another x-ray image taken by imaging system ofthe system for non-destructive testing is shown. The resistive wire 7 ofthe fusion socket 8 is shown wrapped in a spiral within the fusionsocket 8. Again, there is an uneven spiral 110 of the resistive wire 7,in this case one can see the top portion of the resistive wire 7 skewedtowards the right as it was likely that the plastic pipe 6 to the rightof FIG. 16 bent downward before substantial cooling occurred. This isfurther evident by the gaps 112 between the ends of the two plasticpipes 6 and the fusion socket 8.

Referring to FIG. 17 , another x-ray images of a fusion tee 8A taken byimaging system of the system for non-destructive testing is shown. Torepeat, in the case of a fusion tee 8A, it is important not to insertthe ends of the plastic pipe 6 too far into the fusion tee 8A. If theends of the plastic pipe 6 are inserted too far into the fusion tee 8A,the ends of the plastic pipe 6 will block flow of the fluid to the thirdleg of the fusion tee 8A. In the example of FIG. 17 , the end 126 of oneof the plastic pipes 6 intrudes upon the third leg of the fusion tee 8A,totally occluding fluid flow to/from the third leg of the fusion tee 8A.

Referring to FIGS. 19 through 21 , x-ray images of an electrofusionservice tee taken by imaging system of the system for non-destructivetesting are shown. In FIG. 18 , a failure report of the prior art isshown in which one tap tee 8D remains connected to the plastic pipe 6but another tap tee 8 d (not shown) fell off of the plastic pipe 6 atthe location of the tap hole 128. In FIG. 19 , reasons for such failureare evident as the same fuser likely made both fuses. There is a blowout 130 near the electrical contact 9D and several of the resistivewires 7D have shorted 131, as the tap tee 8D was likely moved before theplastic of the tap tee 8D and the plastic pipe 6 cooled enough toharden. The same is shown from the side in FIG. 20 and the uneven spiral110 appears to have a short between turns of the resistive wire 7D isshown from the side in FIG. 21 .

Many of the above issues with butt fuses, fusion socket 8, fusion tees8A, tap tees 8D, etc., are not evident until either a destructive testis performed or a field failure occurs. Being that the plastic pipes 6are often buried underground, often under roadways, sidewalks, parkinglots, etc., a failed fuse is often very difficult to find and expensiveto repair.

Referring to FIG. 22 , a schematic view of the system fornon-destructive testing is shown. The source of radiation 150 (e.g.,x-ray radiation) is shown in position, in this example, above a fusionsocket 8 that connects two sections of the plastic pipe 6. The source ofradiation 150 is remotely controlled to emit radiation (e.g., x-rays)through a lens 152 and directed at the fuse, in this case, the fusionsocket 8, though any thermal fuse of two or more plastic parts (e.g.,plastic pipes 6). In some embodiments, the lens 152 is made of amaterial such as Beryllium which allows enough radiation out of thesource of radiation so as to penetrate the fuse, but a lower amount ofradiation so as to not radiate harmful radiation towards operators ofthe source of radiation.

On the other side of the fuse (or in this example, fusion socket 8) is ascanning plate 154 such as a phosphorous plate. The scanning plate 154records exposure to radiation across the surface of the scanning plate154. After the source of radiation 150 is activated for a period of timeand the scanning plate 154 is exposed to the radiation through the endsof the plastic pipe 6 and the fusion socket 8, the scanning plate 154 isremoved and places upon a scanner 160. The scanner scans an image fromthe scanning plate 154 while also erasing the scanning plate 154 so thatit is ready for the next scan. The scanner 160 is, for example, computedradiography scanner and the amount of radiation received at each pixelof the scanning plate is recorded to create an x-ray image of the fuse.An example of a scanner 160 is a computed radiography scanner such asthe CR 4100 produced by Virtual Media Integration of Pensacola, Florida,USA. Note that as technology progresses, it is fully anticipated thatthe image generation will be automatic from the scanning plate 154without need of a separate scanner 160.

The scanner 160 is operatively coupled to a computer 500 (see FIG. 25 )where the x-ray image is stored, enhanced, recognized, and/or displayedon, for example, a display 586. Note that it is fully anticipated thatinstead of using a plate system, a sensor array (scanner) be positionedat the fuse 6 and the x-ray image is scanned by the sensor array andcopied directly into the computer.

In some usage scenarios, the system for non-destructive testing isinstalled in a vehicle (e.g., a van) so that the images are availablefor review immediately and any unacceptable fuses be recognized andremoved (cut out and re-fused) before burying underground.

As it is important to archive results of testing and to provide feedbackto the company performing the fusing and the employees performing thefusing (fusers), the images are often saved in storage such aspersistent memory 574 (see FIG. 25 ) of the computer 500 and the images(and reports) are anticipated to be transferred to remote storage eitherusing removable storage removably interfaced to the computer 500 or bytransferring the images (and reports) over a network 502 (see FIG. 25 )for remote storage, viewing, analysis, feedback, etc.

In some embodiments, software running on the computer 500 recognizessome or all flaws using image enhancement and recognition. For example,as the resistive wires 7 are typically factory wound in an evenly spacedspiral. Image recognition detects the contrast of the resistive wires 7against the plastic of the fusion socket 8 and the plastic of theplastic pipe 6 and the software measures the continuous distance betweeneach turn/loop of the resistive wire 7, detecting if two adjacent turnsof the resistive wire 7 are too close or too far from each other. In asimilar way, the software locates each end of the plastic pipe 6 withinthe fusion socket 8 and determines if each end is close enough to eachother. As for a fusion tee 8A, the software locates each end of theplastic pipe 6 within the fusion tee 8A and determines if the ends ofthe plastic pipe 6 encroach upon the third leg of the fusion tee 8A.

Referring to FIGS. 23-24 , exemplary flow diagrams of the system fornon-destructive testing are shown. The flow begins with erasing 400 thescanning plate 154 (if the scanning plate 154 was not previouslyerased). Now the source of radiation 150 and the scanning plate 154 arepositioned 402 on opposite sides of the fuse. Note that often images ofthe same fuse are captured at different angles to detect problems thatare not evident from only one angle.

Now the source of radiation 150 is enabled to emit 404 radiation (e.g.,x-rays). Once the source of radiation 150 is stopped, the scanning plate154 is moved 406 to the scanner 160 and scanned to extract the x-rayimage of the fuse. The x-ray image of the fuse is then stored 408 (e.g.,in persistent memory 574 of the computer). If there are more fuses totest 410, the above is repeated, otherwise the non-destructive testingis complete.

In FIG. 24 , an exemplary program flow of an automated fuse qualitycheck is shown for one x-ray image, though the same is applied to allx-ray images as desired. In this, the software reads 420 the x-ray image(e.g., from persistent memory 574) and analyzes 422 the x-ray image by,for example, enhancing the x-ray image, detecting the resistive wires 7,detecting outer edges and ends of the plastic pipes 6, detecting inneredges of the socket 8/8A/8D, etc.

In this example, the software determines if there is skewing 426 of theresistive wires 7, and if there is skewing 426 of the resistive wires 7,the software records the skewing 426 in the report for that fuse. Notethat such skewing is determined by a pre-set tolerance of skewing of theresistive wires 7 based upon local or industry standards.

Now, the software determines if there is/are gaps 428 between the endsof the plastic pipes 6, and if there is/are gaps 428 between the ends ofthe plastic pipes 6, the software records the gaps 430 in the report forthat fuse. Note that an acceptable gap is determined by a pre-set gaptolerance based upon local or industry standards.

Now, the software determines if there is/are coupling gaps 432 betweenthe ends of the plastic pipes 6 and the fusion socket 8/8A, and if thereis/are coupling gaps 432, the software records the coupling gaps 434 inthe report for that fuse. Note that an acceptable coupling gap isdetermined by a pre-set gap tolerance based upon local or industrystandards.

Next, a report is generated 436 including the location of the fuse, anidentification of the fuser, etc.

Also, in some embodiments, a global fuser database is updated 438 withqualitative measurements of the fuse as well as issues found with thefuse. In this way, each fuser will have a history showing a percentageof faulty fuses, overall quality numbers, quality trajectories (e.g.,quality improving or falling), etc., for use in determining how many ofthat fuser's fuses need inspection, performance reviews, etc. Forexample, if 50% of fuses made by a particular fuser are faulty, then allfuses by that fuser need to be inspected and that fuser needs feedbackand/or disciplinary action, etc.

Referring to FIG. 25 , a schematic of a typical computer system as usedby the system for non-destructive testing is shown. The example typicalcomputer system 500 represents a typical device used as in the Referringto. This typical computer system 500 is shown in its simplest form.Different architectures are known that accomplish similar results in asimilar fashion and the present invention is not limited in any way toany particular computer system architecture or implementation. In thisexemplary computer system, a processor 570 executes or runs programs ina random-access memory 575. The programs are generally stored within apersistent memory 574 and loaded into the random-access memory 575 whenneeded. The processor 570 is any processor, typically a processordesigned for computer systems with any number of core processingelements, etc. The random-access memory 575 is connected to theprocessor by, for example, a memory bus 572. The random-access memory575 is any memory suitable for connection and operation with theselected processor 570, such as SRAM, DRAM, SDRAM, RDRAM, DDR, DDR-2,etc. The persistent memory 574 is any type, configuration, capacity ofmemory suitable for persistently storing data, for example, magneticstorage, flash memory, read only memory, battery-backed memory, magneticmemory, etc. The persistent memory 574 is typically interfaced to theprocessor 570 through a system bus 582, or any other interface as knownin the industry. In some embodiments, the persistent memory 574 hasstored therein a database of fusers (person who fuses the plastic pipes6) and each fuse performed by a specific fuser in the database of fusersis associated with that fuser and/or the quality of the fuse isassociated with that fuser. In this way, quality feedback is availablefor the fusers (e.g., 1% of the fuses made by a certain fuser are bad).

Also shown connected to the system bus 582 is a network interface 580(e.g., for connecting to other computers through a network 502), agraphics adapter 584 and a keyboard interface 592 (e.g., UniversalSerial Bus—USB). The graphics adapter 584 receives information from theprocessor 570 and controls what is depicted on a display 586 (e.g.,displaying of x-ray images). The keyboard interface 592 providesnavigation, data entry, and selection features. In some embodiments, thedisplay 586 is a large screen graphics display for field view andanalysis of fuses (e.g., to show and explain the issues to the fuser,etc.).

In general, some portion of the persistent memory 574 is used to storeprograms, executable code, data, scanned x-ray images, etc.

The peripherals are examples and other devices are known in the industrysuch as pointing devices, touch-screen interfaces, speakers,microphones, USB interfaces, Bluetooth transceivers, Wi-Fi transceivers,image sensors, temperature sensors, etc., the details of which are notshown for brevity and clarity reasons.

Equivalent elements can be substituted for the ones set forth above suchthat they perform in substantially the same manner in substantially thesame way for achieving substantially the same result.

It is believed that the system and method as described and many of itsattendant advantages will be understood by the foregoing description. Itis also believed that it will be apparent that various changes may bemade in the form, construction and arrangement of the components thereofwithout departing from the scope and spirit of the invention or withoutsacrificing all of its material advantages. The form herein beforedescribed being merely exemplary and explanatory embodiment thereof. Itis the intention of the following claims to encompass and include suchchanges.

What is claimed is:
 1. An apparatus for non-destructive testing of afuse between a plurality of plastic pipes inserted into a fusion socket,the apparatus comprising: a source of radiation selectively operated toemit an x-ray radiation; a computer; a scanning plate for receiving thex-ray radiation; a scanner, the scanner operatively coupled to thecomputer; a display operatively coupled to the computer; wherein thesource of radiation is positioned on one side of the fuse between theplurality of plastic pipes and the scanning plate receives the x-rayradiation that passes through the fuse while the source of radiation isselectively operated to emit the x-ray radiation; and wherein after thesource of radiation is discontinued, the scanning plate is moved to thescanner and the scanner scans the scanning plate into an x-ray image andthe x-ray image is transferred into a storage of the computer; whereinthe computer analyzes the x-ray image of the fuse and recognizes aposition of each of the plurality of plastic pipes to determine if thefuse is a good fuse or a bad fuse by the position of each of theplurality of plastic pipes.
 2. The apparatus of claim 1, furthercomprising a lens affixed to the source of radiation, the lens is madeof Beryllium and the lens allows enough radiation out of the source ofradiation so as to penetrate the fuse.
 3. The apparatus of claim 1,further comprising a database of fusers and each x-ray image isassociated with a fuser from the database of fusers.
 4. The apparatus ofclaim 1, wherein the plurality of plastic pipes is two plastic pipes andwhen the computer analyzes the x-ray image of the fuse, a bad fuse isdetermined when the position of a first one of the two plastic pipes isseparated by a second one of the two plastic pipes by a gap that isgreater than a predetermined distance.
 5. The apparatus of claim 1,wherein the plurality of plastic pipes is two plastic pipes and when thecomputer analyzes the x-ray image of the fuse, a bad fuse is determinedwhen the position of an end of a first one of the two plastic pipes isoffset from a lengthwise center of the fusion socket by a distance thatis greater than a predetermined distance.
 6. The apparatus of claim 1,wherein the plurality of plastic pipes is three plastic pipes and whenthe computer analyzes the x-ray image of the fuse, a bad fuse isdetermined when the position of a first one of the three plastic pipeswill impede flow of a fluid to a second one of the three plastic pipes.7. A method of determining if a fuse between plastic pipes within afusion socket is a bad fuse, the method comprising: placing a source ofx-ray radiation that emits x-ray radiation on one side of the fuse;holding a scanning plate to an opposing side of the fuse; initiatingemission of the x-ray radiation; stopping emission of the x-rayradiation; removing the scanning plate from the opposing side of thefuse and moving the scanning plate to a scanner; scanning the scanningplate, creating an x-ray image of the fuse; transferring the x-ray imageof the fuse into a storage of a computer; displaying the x-ray image ona display of the computer; and visually analyzing the x-ray image of thefuse to determine if the fuse is the bad fuse by recognizing a positionof each of the plastic pipes to determine if the fuse is the bad fuse bythe position of each of the plastic pipes within the fusion socket. 8.The method of claim 7, further comprising inserting a lens between thesource of radiation and the fuse, the lens is made of Beryllium and thelens attenuating radiation leaving the source of radiation so as topenetrate the fuse.
 9. The method of claim 7, further comprising a stepof associating each x-ray image with a fuser from a database of fusers.10. The method of claim 7, wherein the plastic pipes are two plasticpipes and wherein in the step of analyzing the x-ray image of the fuseto determine if the fuse is the bad fuse includes determining that thefuse is the bad fuse when the position of a first one of the two plasticpipes is separated by a second one of the two plastic pipes by a gapthat is greater than a predetermined distance.
 11. The method of claim7, wherein the plastic pipes are two plastic pipes and wherein in thestep of analyzing the x-ray image of the fuse to determine if the fuseis the bad fuse includes determining that the fuse is the bad fuse whenthe position of an end of a first one of the two plastic pipes is offsetfrom a lengthwise center of the fusion socket by a distance that isgreater than a predetermined distance.
 12. The method of claim 7,wherein the plastic pipes are three plastic pipes and wherein in thestep of analyzing the x-ray image of the fuse to determine if the fuseis the bad fuse includes determining that the fuse is the bad fuse whenthe position of a first one of the three plastic pipes will impede flowof a fluid to a second one of the three plastic pipes.
 13. A method ofdetermining if a fuse between plastic pipes within a fusion socket is abad fuse, the method comprising: placing a source of x-ray radiation onone side of the fuse; receiving the x-ray radiation an opposing side ofthe fuse; initiating emission of the x-ray radiation; creating an x-rayimage of the fuse from the radiation received at the opposing side ofthe fuse; storing the x-ray image in a storage of a computer; stoppingemission of the x-ray radiation; displaying the x-ray image on a displayof the computer; and reading the x-ray image and determining if the fuseis the bad fuse by finding, in the x-ray image, any issue of the groupconsisting of a gap between two of the plastic pipes being greater thana predetermined distance, an end of one of the plastic pipes beingfurther than a second predetermined distance from a length-wise centerof the fusion socket, and the end of one of the plastic pipes beinginserted to far within the fusion socket, thereby blocking flow to asecond one of the plastic pipes.
 14. The method of claim 13, furthercomprising inserting a lens between the source of radiation and thefuse, the lens is made of Beryllium and the lens attenuating radiationleaving the source of radiation so as to penetrate the fuse.
 15. Themethod of claim 13, wherein in the step of receiving the x-ray radiationan opposing side of the fuse, a scanning plate receives the x-rayradiation and in the step of creating the x-ray image of the fuse fromthe radiation received at the opposing side of the fuse comprisesscanning the scanning plate.
 16. The method of claim 15, furthercomprising a step of erasing the scanning plate.
 17. The method of claim13, further comprising a step of associating each x-ray image with afuser from a database of fusers.
 18. The method of claim 13, wherein thestep of determining if the fuse is the bad fuse is performed by thecomputer, wherein the plastic pipes are two plastic pipes and whereinwhen a position of a first one of the two plastic pipes is separated bya second one of the two plastic pipes by a gap that is greater than thepredetermined distance, the fuse is bad.
 19. The method of claim 13,wherein the step of determining if the fuse is the bad fuse is performedby the computer, wherein the plastic pipes are two plastic pipes andwherein when a position of an end of a first one of the two plasticpipes is offset from a lengthwise center of the fusion socket by adistance that is greater than the second predetermined distance, thefuse is bad.
 20. The method of claim 13, wherein the step of determiningif the fuse is the bad fuse is performed by the computer, wherein theplastic pipes are three plastic pipes and wherein when when a positionof a first one of the three plastic pipes will impede flow of a fluid toa second one of the three plastic pipes, the fuse is bad.